View
283
Download
8
Category
Preview:
Citation preview
Kuraray Co., Ltd.- Since 1926 -
ProfileEstablished: June 24, 1926Capital: 89 billion (as of March 31, 2008) Net Sales: 418 billion (as of March 31, 2008, consolidated) Employees: 6,770 (as of March 31, 2008, consolidated)
Major Businesses - Vinyl acetate derivatives (Poval, EVAL, KURALON, etc.) - Isoprene chemicals (TPE, Aroma chemicals, Pharmaceuticalintermediates, etc.)
- Man-made leather - Environment-related (PVA gel, Industrial membranes, etc.) - Medical (Dental materials, Hemocatharsis adsorption devices, etc.)
Kurarays History1926Kurashiki Kenshoku
1920s
PVA film commercialized Co.,Ltd. established 1960s 1964 Polyester staple / CLARINO 1928 Rayon commercialized commercialized1962
1940s
1949Renamed to Kurashiki Rayon Co., Ltd.
1970s
1969 Polyester filament commercialized 1970 Renamed to Kurary Co., Ltd.1972
Contact lenses / EVAL / nonwoven fabrics /isoprene chemicals commercialized 1978 Dental material commercialized
1950s
1950 KURALON commercialized 1958Poval commercialized (started to sell at a market)
Kurarays History2002
1980s 1983 Cement reinforcingKURALON developed
2000s2002 2004
1986 Production of EVAL resin
started at U.S.1990 VECTRAN / SEPTON
1990s
commercialized 1998 KURALON K-II cmmercialized 1999 Production of Poval resin started at Singapore Production of EVAL resin started at Belgium GENESTAR commercialized
2005
Production of Rayon ceased Acquisition of Clariants PVArelated products Production of SEPTON started at U.S. Acquisition of the PVB film business of HT Troplast Acquisition of VECTRAN business of U.S.-based Celanese Advanced Materials Inc. POVAL ASIA PTE LTD acquired and company made a subsidiary
2008 All outstanding shares of
Net Sales (consolidated)417.6)
400
385.3 375.1 354.9 332.1
300
200
0
03
04
05
06
07
FY
Round off the figure to the nearest 0.1 billion
Profit (consolidated)
50
48.1
Operating Income Net Income40 33.2 30 28.0 21.2 20 15.2 10 18.5 38.3
40.2
25.6 22.4
0
FY03
FY04
FY05
FY06
FY07
Round off the figure to the nearest 0.1 billion
Market PositionKuraray holds the worlds No.1 market share in the following businesses.Poval, polyvinyl alcohol resin (35%) PVA film for LCDs (80%) EVAL, ethylene-vinyl alcohol copolymer (70%) Vinylon, polyvinyl alcohol fiber (80%) Clarino, man-made leather (25%)(Estimated by Kuraray)
Maintaining International CompetitivenessAs of July,2008
Products for Environmental BusinessHigh-performance High-performance membranes membranes High-precision High-precision physical physical separation separation Purification of water Purification of water for potable use. for potable use. Water treatment for Water treatment for industrial uses. industrial uses. Wastewater treatment Wastewater treatment and reuse. and reuse. Municipal and Municipal and industrial wastewater industrial wastewater treatment and treatment and sludge reduction sludge reduction
PVA gel PVA gel
High-Performance High-Performance biological treatment biological treatment for wastewater for wastewater
Activated Activated carbon carbon
Absorption of contaminants Absorption of contaminants in water and gas in water and gas
Kuraray Chemical Kuraray Chemical Co., Ltd. Co., Ltd. (No.1 brand in Japan) (No.1 brand in Japan
Kuraray Hollow Fiber Membrane Products
Particle Size and Membrane TechniquesReverse Ultra Filtration Osmosis(RO) (UF) Micro Filtration (MF) Polyvinylidene-fluoride (hydrophilic) General Filtration
Lineup of Kuraray membrane0.001 10 S u c r o s e Io n H e m o glo bin
Polysulfone coated with PVA Polysulfone
Large pore
0.01 J a p a n e s e E n c e p h a li t i s V ir u s C o ll o i d a l S ili c a
0.1
1 B e e r Y e a s t
10m
ProteinsIon, Low Molecular Weight
Viruses
Bacteria Micro-particle Region
Colloidal Region
C r y p t o s p o ridiu m
E r y t h r o c y t e
E m ulsio n
S h i g e ll a
Features of Kuraray Membrane Products1. Material of the membrane (PVA-coated PSF and PVDF)Kurarays PSF and PVDF membranes have a hydrophilic property, which is achieved by a special coating technology with polyvinyl alcohol resin (PVA) (patented in Japan). The hydrophilic property has less fouling (see below). These products have heat & chemical resistant features, too.
Results of protein adsorption test More foulingNo treatment
Hydrophilic treatment
Less foulingKuraray PVDF Kuraray PSF Other PSF Other PVDF
Features of Kuraray Membrane Products2. Loose end structure of membrane element for external pressure filtration
Developed by Kuraray Suspended solids can be easily removed.
Others Suspended solids tend to accumulate at the lower potting part.
Dead end filtration suitable for raw water with high turbidity Drain
Risks of membrane fouling and breaking
Features of Kuraray Membrane Products3. Cartridge styleOnly the elements need to be replaced (low replacement cost).
4. Stainless-steel housingCan be installed outdoors.
5. External dead-end filtrationSimple pretreatment, simple equipment configuration, low energy.
6. Unique physical cleaning technology (patented in Japan)Effluent tank and pump for backwashing are not necessary. High recovery (No treated effluent is used for backwashing).
Unique Physical Cleaning Method (patented)Filtration Effluent Backwashing Compressed air Air scrubbing Drain
Influent
Air Suspended solids are accumulated on the membrane surface during filtration. Compressed air is injected into the effluent side. The water inside the module flows back and the solids on the membrane are exfoliated. Suspended solids are further removed and dispersed by air scrubbing. The concentrate in the module is drained from the bottom.
Applications of Kuraray Membrane Products 1Ultra pure water treatmentPretreatment of RO membraneFinal filter of ultra pure water plant Point of use Recycle2Potable water treatment
3Purification of beverages, chemicals 4Recycle Hot water Silicon Absorbent for absorption refrigerator (LiBr solution)
R a w
W a t e r
C l a rif y
A c tiv a t e d C a r b o n P r o t e c t i o n F il t e r
Pretreatment
pure water recycle process
Ultra Pure Water Production Flow
R O M e m b r a n e D e g a s sin g
Primary system
UF Cartridge Type C, S Point of use UF Cartridge Type C, S
Io n E x c h a n g e
U V O xid a tio n
Sub system
Io n E x c h a n g e U F M e m b r a n e
Pre-treatment for RO MembranesGS module pore size: 0.02m m. surface area: 42 m2
Standardized by many engineering companies in Japan (Kurita, Nomura, Hitachi Plant etc.)Top market share
GS (external pressure)
Kurita Water Industries Ltd.
Wastewater Treatment and RecycleInorganic wastewater of semiconductor industries (dicing, back-grind, and beveling process) and FPD industries (grinding and rinsing process of the glasses for LCD and PDP).
Over 100 applications SF moduleEnergy saving because of external dead end filtration.
Recycle as raw water for ultra pure water
SF element (external Membrane surface area
pore size0.02m
T7 tank module : element7 Membrane surface area49
Kuraray Products for Semiconductor and Photovoltaic Industries recycle of silicon and ultra pure waterRecycle of coolant Recycle of coolant for wire-saw process for wire-saw processSilicon material Multi-crystal silicon ingot Recycled by filtration with Kuraray original large pore (2.5m) membrane. Ordinary waste Silicon wafer PV cell PV module
Slicing Semiconductor Single-crystal ingot Silicon recycle Ingot processing Dicing, back grindingOriginal loose-end structure
Silicon Silicon (wasted or Ordinary (wasted or recycled) recycled) waste
Recycle of Recycle of ultra pure ultra pure water and water and silicon silicon
Recycle of Recycle of ultra pure ultra pure water water
Hollow fiber membrane High efficiency to drain suspended solids
Suitable for wastewater with inorganic particles
SF for Wastewater Treatment and Recycle : Main Applications and UsersField Semiconductor LCD glass LCD panel LCD color filter PDP glass Process dicing, back grinding, beveling glass grinding rinsing rinsing grinding, rinsing Principal users (companies) R, S, S, F, etc. C, N, etc. S, P, etc. T, etc P, etc
Over 100 applications
Small Sized UF Type-C and Type-S *Small size (2m2 for Type-S and 4m2 for Type-C) *Two filtration limits (MW cut off: 5,000 and 13,000) *External dead-end filtration (unique for UF, energy saving) *Cartridge style (Type-C) (easy and cost effective for replacements)
Type-C (4m2)
Type-S (2m2)
Small Size UF Type-C and Type-SExamples of applications Semiconductor and electronics industries: Filtration of ultra pure water. (Production facilities and point of use) Medical and pharmaceutical industries: Production of aseptic and pyrogen-free water. Other water purification
Applications of Kuraray Membrane Products1Ultra pure water treatment Pretreatment of RO membrane Final filter of ultra pure water plant Point of use Recycle
2. Potable water treatment
3Purification of beverages, chemicals 4Recycle Hot water Silicon Absorbent for absorption refrigerator (LiBr solution)
Potable Water Treatment ProcessRaw Water River, Well, Lake, Spring etc. Coagulating Sedimentation Coagulant Sand Filtration Disinfection Distribution
Most Common, Cheap
O & M is troublesome (small scale) Pathogenic protozoa (Cryptosporidium)
Raw Water
Filtration by
Disinfection
Distribution
High cost expense of membranes) High energy cost
High quality of effluent perfect removal of pathogenic protozoa Automatic O & M
Over 600 applications in Japan (2007)
Potable Water Treatment ProcessFirst large potable water plant using membrane filtration in Japan.
Internal pressure UF (Installed in 1997)Ogose Town, Saitama Pref. Produced by Kurita Water Industries Ltd.
4,000 m3/d
Large Pore: External Dead-end FiltrationRaw Water River, Well, Lake, Spring etc. Coagulating Sedimentation Sand Filtration Coagulant
Large Pore 2.0m
Disinfection
Distribution
Worlds largest porosity for hollow fiber.
Removal of pathogenic protozoa (Cryptosporidium). Post-treatment of existing process. Cost effective High flux Small amount of modules
Low pressure Pump-free operation
Large Pore: Removal of CryptosporidiumOuter surface Inner surface membrane
Cross section
AppearanceModel particles of Cryptosporidium (5m)
Type of Filtration Rapid Sand Filtration Slow Sand Filtration Membrane Filtration
Removal Capability 99.7 99.9Same as ordinary MF
Porem
99.9999
> >99.9999% > >99.99999% Hirata, Powder and Industry, Vol.34,No.3(2002)
Large Pore: Pump-free SystemOrdinary MF/UF systemRaw WaterRaw Water Tank
Feed pump is necessary. ~30mH
Ordinary UFMF
Effluent
Large Pore systemRaw WaterRaw Water Tank
Pump-free system is available. (low power expense)
35m of water head
Large pore
Effluent
Large Pore: Example of InstallationOne of the largest potable water plant using membrane filtration in Japan. Raw water tank Filtration units Disinfection
30,000 m3/d(Installed in 2004) Distribution
Shallow well
Pump-free operation
Hamura City, Tokyo Pref. Produced by Suido Kiko Co., Ltd.
Applications of Kuraray Membrane Products1Ultra pure water treatment Pretreatment of RO membrane Final filter of ultra pure water plant Point of use Recycle 2Potable water treatment
3Purification of beverages, chemicals4Recycle Hot water Silicon Absorbent for absorption refrigerator (LiBr solution)
Food IndustriesPurposes of filtration for food industries = Removal of bacteria, enzyme, suspended solidOverwhelmingly top market share in Japan
1. SakeOver 400 plants (40%) 2. Soy sourceabout 40 plants 3. Vinegar10 plants 4. OthersSoft drinks, beer, etc.Acid-resistant module
Applications of Kuraray Membrane Products1Ultra pure water treatment Pretreatment of RO membrane Final filter of ultra pure water plant Point of use Recycle 2Potable water treatment 3Purification of beverages, chemicals
4RecycleHot water Silicon Absorbent for absorption refrigerator (LiBr soln.)
Filtration of Hot Water (recycle of boiler drainage)
Membrane: SF with heat resistance up to 99 Pore size : 0.1 m Membrane surface area 7 Filtration styleExternal dead-end
Standardized by Self-Defense Force
Over 150 applications
Absorption Refrigerator: Recycle of Absorbent (LiBr solution) Overwhelminglytop share in Japan
PSV filter
Contamination of absorbent
Reduction of machine life. Decrease of freezing capability. Increase of fuel consumption.
Kuraray New Membrane ModulesLaunched in 2009
Smaller (2m2)
Larger (25m2)
Large-pore membrane for potable water
Submerged PVDF membrane (8m2)
RO-pretreatment membrane50m2
PVA-gel Beads A Carrier for Immobilization of Microorganisms
Conventional Biological Wastewater TreatmentLarge tank, large footprint Wastewater (organic contaminant) AirSludge return
Microbial degradation
Solid-liquid separationSedimentation tank
Discharge supernatant Large amount of industrial waste
[Excess sludge]Microorganism grows by eating organic substances (about 50% of organic substances (BOD) converts to CO2/H2O and the rest converts to excess sludge). The excess sludge must be wasted periodically.
Activated sludge (sludge is the mixture of bacteria, protozoa and metazoa.)
PVA-gel Beads: A Bio-carrierMaterial: Polyvinyl alcohol (PVA) Size: 4- or 5-mm beads Specific gravity: 1.025
Protozoa, MetazoaMicroscopic structure Microscopic structure
Only bacteria enter PVA gelOnly this retained
Bacteria Protozoa Metazoa
Examples of bio-carriers
Microscopic structure Microscopic structure
Kuraray PVA-GelMost of them do not have porous structures like PVA-Gel. (bacteria is retained only on the surface with protozoa and metazoa.)
Characteristics of PVA-GelPVA-gel has a micro-porous structure in which PVA-gel has a micro-porous structure in which bacteria can be retained. bacteria can be retained. Quite high load is possible. Quite high load is possible. (5 times or much higher than conventional activated sludge) (5 times or much higher than conventional activated sludge) PVA-gel can also be used for biological nitrification PVA-gel can also be used for biological nitrification and denitrification processes. and denitrification processes. The amount of excess sludge can be reduced or eliminated. The amount of excess sludge can be reduced or eliminated. (We have some special techniques to reduce excess sludge (We have some special techniques to reduce excess sludge dramatically with PVA-gel.) dramatically with PVA-gel.)
Comparison of CapabilityConventional system Activated sludge tank Tank volume can be reduced to 1/6, or volume load can be increased by 6 timeskg/m3-
Mixture of Bacteria, protozoa, metazoa, etc.
PVA gel (10 % vol. packing)Only effective bacteria PVA gel tank Countless bacteria are retained in PVA gel.
kg/m3d
4
3 2 1Volume load
x6
0
Activated sludge
PVA gel PVA
High Efficiency and Low Excess SludgeConventional system Activated sludge tankExcess sludge (about 50% of BOD) Sedimentation tank
Effluent
PVA gel (10 % vol. packing)Effluent Coagulant PVA gel tankExcess sludge (about 30% of BOD) No sludge return
Activated sludge Sludge is returned only tothe activated sludge tank.
Effluent
Nitrogen removal is also possible with an different process.
Excess sludge (about 20% of BOD)
Sludge Problem in JapanSolid waste production (2002) 1% 2% 2% 2% 4% 2% 2% 6%
Running cost for WWTPsChemical cost 7%
Sludge 47%
Construction materials 15%
Total Amount 44,600,000 ton
Electric cost 25%
Sludge disposal cost 50-70%
Animal waste 17%
Sludge reduction challenge
PVA Gel: Sludge Reduction SystemConventional system Activated sludge tankSedimentation tank
Effluent
Excess sludge(about 50% of BOD)
New PVA-gel systemAutolysis PVA gel tank Sludge reduction tank Solid-liquid separation
Effluent
Smaller tanks
Almost no excess sludge (organic)
The reduction of the excess sludge can be achieved by the autolysis (endogenous decay) of the sludge in the sludge reduction tank.
Sludge Reduction with PVA Gel: Endogenous Decay Total OxidationOther carriers, activated sludgeProtozoa, metazoa, and bacteria, grow on the surface. Protozoa and metazoa
PVA GelBacteria grow inside PVA gel
Protozoa Metazoa Bacteria
Excess sludge0.08
Bacteria
(/day) Sludge reduction rate0.06 0.04 0.02
Only this retained in PVA gel
Bacteria Protozoa Metazoa
Sludge reduction becomes easier
0 Activated sludge PVA gel
Kuraray Sludge Reduction SystemSedimentation type TYPE-SSludge reduction tank
Sedimentation tankEffluent The most cost effective for conversion of existing activated sludge process
PVA gel tank
Membrane filtration type TYPE-MEffluent
*No sedimentation tank *Smaller sludge reduction tank(higher MLSS)
Submerged membrane
*Recyclable water
Patented in USA, European and Asian countries. Nitrogen removal is also possible with a different process
Example: Sludge Reduction System (Type-S)Kuraray Saijo Plant (400m3/d)Gel separator (2 mm mesh)
BOD removal and sludge reduction BOD removal and sludge reduction
Sludge reduction tank
PVA Gel tank (BOD removal)
No excess sludge No excess sludge for 10 years! for 10 years!X 1.5 Sedimentation tank
Example: Sludge Reduction System (Type-M, in Taiwan)RO membrane PVA gel + sludge reduction (installed underground)Biodegradation of organic contaminant Sludge elimination by autolysis
85% of the wastewater can be recycled as ultra pure water. Greatly reduced excess organic sludge by autolysis.
RO membrane Submerged membranePVA gel tank Sludge reduction tank
Technical Service System in JapanEnd user Inquiry Sample Engineering firm Test result & proposal Kuraray 1. Small scale testing in Kurarays laboratory: (1) Evaluation of filtration behavior. (flux, physical cleaning, chemical cleaning) (2) Evaluation of biological treatability. (3) Analysis (Influent, effluent). 2. Pilot-testing units available for long-term tests Kurarays technical services are sought-after in Japan Biological treatment test unit Filtration test unit
Thank you
Recommended